Plastic fasteners, needles for dispensing and method of manufacture

ABSTRACT

A needle ( 51 ) particularly well-suited for use in the dispensing of plastic fasteners ( 21 ) of the type comprising a filament ( 15 ) having a cross-bar ( 23 - 1, 23 - 2 ) at a first end thereof, each of the cross-bar ( 23 - 1, 23 - 2 ) and the filament ( 15 ) including a first flat side, the first flat sides of the cross-bar ( 23 - 1, 23 - 2 ) being coplanar. The needle ( 51 ) includes a stem portion ( 53 ). The stem portion ( 53 ) terminates in a tip ( 57 ) at its front end and is shaped to define a longitudinal bore ( 59 ) and a longitudinal slot ( 61 ) for receiving the filament ( 15 ) and the cross-bar ( 23 - 1, 23 - 2 ). The longitudinal bore ( 59 ) has a first flat side, and the longitudinal slot ( 61 ) has a first flat side, wherein the flat sides are coplanar.

BACKGROUND OF THE INVENTION

[0001] The present invention relates to the dispensing of plasticfasteners of the type that are used, for example, to attach tags toarticles of commerce.

[0002] Plastic fasteners of the type comprising an elongated flexiblefilament having a first cross-bar at one end and a second cross-bar (orother enlargement, such as a paddle or a knob) at the opposite end arewell-known and have been widely used in a variety of applications, suchas in the attachment of merchandise tags to articles of commerce, in theattachment of buttons to garments, in the lasting of shoes, and invarious packaging applications. Typically, such plastic fasteners aremass-produced by molding processes into either one of two differenttypes of assemblies. One such assembly, an example of which is disclosedin U.S. Pat. No. 3,103,666, inventor Bone, issued Sept. 17, 1963 (whichpatent is incorporated herein by reference), is a clip-type assembly,said clip comprising a plurality of fasteners, each such fastenercomprising a flexible filament having a first cross-bar at one endthereof and a paddle or second cross-bar at the opposite end thereof.The fasteners are arranged in a spaced, side-by-side orientation, withthe respective first cross-bars parallel to one another and therespective paddles or second cross-bars parallel to one another, each ofthe first cross-bars being joined to a common, orthogonally-disposedrunner bar by a severable connector. Adjacent second cross-bars orpaddles also may be interconnected by severable connectors extendingtherebetween.

[0003] The aforementioned fastener clip is typically made by injectionmolding. Several commercial embodiments of the above-described fastenerclip have been sold by the present assignee, Avery Dennison Corporation,as DENNISON® SWIFTACH® fastener clips.

[0004] A second type of fastener assembly, an example of which isdisclosed in U.S. Pat. No. 4,533,076, inventor Bourque, issued Aug. 6,1985 (which patent is incorporated herein by reference), is known ascontinuously connected fastener stock. In one type of continuouslyconnected stock, the fasteners comprise a flexible filament having across-bar at one end thereof and a paddle (or second cross-bar) at theopposite end thereof, the respective cross-bars and paddles ofsuccessive fasteners being arranged end-to-end and being joined togetherby severable connectors. In another type of continuously connectedfastener stock, the fastener stock is formed from two elongated andcontinuous side members coupled together by a plurality of cross-linksequidistantly-spaced apart by a distance of 0.25 inch. Individualfasteners having an H-shape, often referred to as “plastic staples,” aredispensed from the fastener stock by cutting the side members atappropriate points between cross-links, thereby yielding individualfasteners having cross-bars of 0.25 inch in length.

[0005] Continuously connected fastener stock is typically made by arotary extrusion process of the type disclosed in U.S. Pat. No.4,462,784, inventor Russell, which issued Jul. 31, 1984, and which isincorporated herein by reference. Said rotary extrusion processtypically involves the use of a rotating molding wheel whose peripheryis provided with molding cavities that are complementary in shape to thedesired fastener stock. To form fasteners, plastic is extruded into thecavities of the molding wheel, and a knife in substantially ellipticalcontact with the wheel is used to skive the molded plastic from themolding wheel. Following molding, the filament portions of the fastenersare typically stretched.

[0006] One consequence of the rotary extrusion process described above,particularly the skiving step thereof, is that the first cross-bar, thefilament, and the second cross-bar (or paddle) are flat on one sidethereof, with the flattened sides of the first cross-bar, the filamentand the second cross-bar all lying in the same plane (see e.g., FIG. 1Bof U.S. Pat. No. 4,462,784). The opposite sides of the first-cross bar,the filament, and the second cross-bar (or paddle) conform to the shapesof the molding cavities and are typically not flat. In the case of thefirst cross-bar, its opposite side is curved, thereby resulting in across-bar whose transverse cross-section has a shape resembling asemicircle or semi-ellipse.

[0007] Tools (often referred to as “tagging guns” or “fastener attachingtools”) for dispensing individual fasteners from continuously connectedfastener stock above are known, examples of such tools being disclosedin the following U.S. patents, all of which are incorporated herein byreference: U.S. Pat. No. 4,039,078, inventor Bone, which issued Aug. 2,1977; U.S. Pat. No. 5,433,366, inventors Deschenes et al., which issuedJul. 18, 1995; U.S. Pat. No. 4,121,487, inventor Bone, which issued Oct.24, 1978; U.S. Pat. No. 5,320,269, inventors Deschenes et al., whichissued Jun. 14, 1994; U.S. Pat. No. 4,955,475, inventors McCarthy etal., which issued Sept. 11, 1990; U.S. Pat. No. 4,456,161, inventorRussell, which issued Jun. 26, 1984; U.S. Pat. No. 5,024,365, inventorBourque, which issued Jun. 18, 1991; and U.S. Pat. No. 4,998,661,inventors Deschenes et al., which issued Mar. 12, 1991.

[0008] Such tools typically comprise a needle, the needle typicallyincluding a stem portion. The stem portion typically is generallycylindrical in shape and has a longitudinally-extending,cylindrically-shaped bore adapted to receive the first cross-bar of afastener. In addition, said stem portion also typically has alongitudinally-extending slot adapted to permit the filament portion ofa fastener to extend therethrough while the first cross-bar of thefastener is disposed in the longitudinal bore of the stem portion. Thestem portion also typically has a tip adapted for insertion into adesired article of commerce. The needle also may include a base portion,said base portion being attached to the rear of the stem portion andbeing adapted to be removably received in the tool. The stem portion andthe base portion may be a unitary structure or, as is more often thecase, the base portion is insert-molded onto the rear end of the stemportion.

[0009] Such tools also typically comprise an ejector rod for ejecting afirst cross-bar from the needle and into the article of commerce and mayalso include a knife or similar severing means for cutting the severableconnector between the first cross-bar being dispensed and its adjacentfirst cross-bar and feeding means for advancing the assembly offasteners in the tool so as to align the forwardmost first cross-barwith the needle.

[0010] One problem that has been noted by the present inventor withrespect to the dispensing of continuously connected fastener stock ofthe type described above using needles of the type described above isthat, whereas the longitudinal bore and the longitudinal slot togetherhave a symmetric transverse cross-sectional shape resembling an inverselollipop (the longitudinal bore being circular in transversecross-section, the longitudinal slot being rectangular in transversecross-section and bisecting said longitudinal bore at the top thereof),the first cross-bar and the filament together have a “d”-shapedcross-section. As a result, a considerable portion of the transversecross-section of the longitudinal bore is not occupied by any of thefirst cross-bar. Because the needle has a circular transversecross-sectional shape, the effect of the bore being larger incross-sectional shape than the fastener is that the needle has an outerwidth or diameter that is larger than that required by the fastener.Consequently, the needle creates an insertion hole in the article ofcommerce that is greater than that required by the fastener. Because itis desirable to minimize the size of the insertion hole (to minimizedamage to the article), the outcome described above is undesirable.

[0011] In addition, because a considerable portion of the transversecross-sectional area of the bore is not occupied by the cross-bar,proper engagement of the cross-bar by the ejector rod and propertranslational movement of the cross-bar through the length of the boredue to action of the ejector rod is not always achieved. This results inoccasional malfunctioning of the tool.

SUMMARY OF THE INVENTION

[0012] It is an object of the present invention to provide a new needleuseful in the dispensing of plastic fasteners of the type having aflexible filament and a cross-bar at a first end thereof.

[0013] It is another object of the present invention to provide a needleas described above that overcomes at least some of the problemsdescribed herein with respect to existing needles.

[0014] According to one aspect of the invention, there is provided aneedle useful in dispensing plastic fasteners of the type comprising afilament having a cross-bar at a first end thereof, said needlecomprising a stem portion, said stem portion terminating in a tip at afront end thereof and being shaped to define a longitudinally-extendingbore and a longitudinally-extending slot, said longitudinally-extendingbore being dimensioned to receive said cross-bar, saidlongitudinally-extending slot being dimensioned to permit said filamentto extend therethrough while said cross-bar is disposed within saidlongitudinally-extending bore, said longitudinally-extending bore havinga first flat side, said longitudinally-extending slot having a firstflat side, said first flat sides of said longitudinally-extending boreand said longitudinally-extending slot being coplanar.

[0015] As can readily be appreciated, the aforementioned needle isparticularly well-suited for use with plastic fasteners wherein each ofthe filament and the cross-bar has a flat side and wherein said flatsides are coplanar. Examples of such fasteners include fasteners formedas part of continuously connected fastener stock made by rotaryextrusion, such as plastic staples. Where plastic staples of the typecomprising a filament and a cross-bar that collectively have a “d”-shapeare to be dispensed using the needle of the present invention, thelongitudinally-extending bore and the longitudinally-extending slot ofthe stem portion of the needle preferably collectively have acomplementary “d”-shaped transverse cross-section. Depending upon theparticular transverse cross-sectional shape of the cross-bar, thelongitudinally-extending bore may have a generally semi-ellipticaltransverse cross-sectional shape, a generally rectangular transversecross-sectional shape, a generally B-shaped transverse cross-sectionalshape, a generally wedge-shaped transverse cross-sectional shape or alike complementary transverse cross-sectional shape. The stem portion ofthe needle is preferably made of a steel or boron/nickel alloy and ispreferably fabricated using electroforming. The needle preferablyfurther comprises a base portion, said base portion being insert-moldedonto a rear end of said stem portion.

[0016] According to another aspect of the invention, there is provided aneedle useful in dispensing plastic fasteners of the type comprising afilament having a cross-bar at a first end thereof, said needlecomprising a stem portion, said stem portion terminating at a front endthereof in a tip, said stem portion having a longitudinally extendingslotted bore, said longitudinally extending slotted bore having a flatside in transverse cross-section.

[0017] The aforementioned needle may be used with a variety of plasticstaples or other plastic fasteners wherein each of the filament and thecross-bar has a flat side and wherein said flat sides are coplanar. Anexample of such a fastener is a plastic staple wherein the filament andthe cross-bar have coplanar flat sides and wherein the cross-bar has a“B”-shape in transverse cross-section. The needle preferably has aslotted bore that is complementary in shape to the cross-bar andfilament of the fastener.

[0018] The present invention is also directed to a novel method offabricating a needle well-suited for use in the dispensing of plasticfasteners of the type comprising a filament having a cross-bar at afirst end thereof. According to one aspect of the present invention,such a method comprises the steps of (a) fabricating an unfinished stemportion, said fabricating step comprising electroforming a metal onto amaster, said master having a “d”-shaped transverse cross-section, andthen removing the master from the electroformed metal; and (b) finishingsaid unfinished stem portion, said finishing step comprising machiningthe unfinished stem portion to yield a finished stem portion, saidfinished stem portion terminating in a tip at a front end and beingshaped to define a longitudinally-extending bore and alongitudinally-extending slot, said longitudinally-extending bore beingshaped to receive said cross-bar, said longitudinally-extending slotbeing shaped to permit said filament to extend therethrough while saidcross-bar is disposed within said longitudinally-extending bore, saidlongitudinally-extending bore and said longitudinally-extending slotcollectively having a “d”-shaped transverse cross-section.

[0019] As can readily be appreciated, the needle made by theaforementioned method is particularly well-suited for use with plasticstaples and other plastic fasteners wherein the filament and thecross-bar collectively have a generally “d”-shaped longitudinalcross-section (said cross-section being defined as being along thelongitudinal axis of the filament and perpendicular to the longitudinalaxis of the cross-bar). Preferably, the metal of the aforementionedmethod is a steel or boron/nickel alloy, and said electroforming steppreferably comprises depositing metal onto said master to a thickness ofabout 0.003-0.005 inch. The above-described method preferably furthercomprises insert-molding a base portion onto a rear end of the finishedstem portion.

[0020] It should be readily understood that, by selecting anappropriately shaped master, one can adapt the above-described needlefabrication method to make a needle particularly well-suited for usewith a fastener whose filament and cross-bar have a coplanar flat sideand whose cross-bar is “B”-shaped in transverse cross-section or to makea needle particularly well-suited for use with a fastener whose filamentand cross-bar have a coplanar flat side and whose cross-bar is shaped toinclude one or more humps.

[0021] The present invention is also directed to a combination of aplastic fastener and a needle. In one embodiment, said plastic fastenercomprises a flexible filament having a cross-bar at a first end thereof,said cross-bar and said flexible filament collectively having agenerally “d”-shaped longitudinal cross-section, said needle comprisinga stem portion, said stem portion terminating in a tip at a front endthereof and being shaped to define a longitudinally-extending bore and alongitudinally-extending slot, said longitudinally-extending bore beingdimensioned to receive said cross-bar, said longitudinally-extendingslot being dimensioned to permit said flexible filament to extendtherethrough while said cross-bar is disposed within saidlongitudinally-extending bore, said longitudinally-extending bore andsaid longitudinally-extending slot collectively having a generally“d”-shaped transverse cross-section.

[0022] Preferably, the fastener cross-bar of the aforementionedcombination is generally semi-elliptical in transverse cross-sectionalshape or is generally rectangular in transverse cross-sectional shape.In a particularly preferred embodiment, the cross-bar is generallyrectangular in transverse cross-sectional shape and has a transversecross-sectional height and a transverse cross-sectional width, saidtransverse cross-sectional height being greater than said transversecross-sectional width and being parallel to the length of said flexiblefilament.

[0023] In another embodiment, said plastic fastener comprises a flexiblefilament having a cross-bar at a first end thereof, each of saidcross-bar and said flexible filament having a flat side, said flat sidesbeing coplanar, said cross-bar being generally “B”-shaped in transversecross-section, said needle comprising a stem portion, said stem portionterminating in a tip at a front end thereof and being shaped to define alongitudinally-extending bore and a longitudinally-extending slot, saidlongitudinally-extending bore and said longitudinally-extending slotbeing complementarily shaped to said plastic fastener.

[0024] The present invention is also directed to a novel plasticfastener. In one embodiment, said plastic fastener comprises a flexiblefilament having a cross-bar at a first end thereof, said cross-bar andsaid flexible filament collectively having a generally “d”-shapedcross-section taken along the length of said flexible filament andtransverse to the length of said cross-bar, said cross-bar having asubstantially rectangular cross-sectional shape with its transverselength being larger than its transverse width.

[0025] In another embodiment, said plastic fastener comprises a flexiblefilament having a cross-bar at a first end thereof, said cross-barhaving a flat side and being generally “B”-shaped in transversecross-section. Preferably, said flexible filament also has a flat side,said flat side of said flexible filament and said flat side of saidcross-bar being coplanar.

[0026] Additional objects, features, aspects and advantages of thepresent invention will be set forth, in part, in the description whichfollows and, in part, will be obvious from the description or may belearned by practice of the invention. In the description, reference ismade to the accompanying drawings which form a part thereof and in whichis shown by way of illustration specific embodiments for practicing theinvention. These embodiments will be described in sufficient detail toenable those skilled in the art to practice the invention, and it is tobe understood that other embodiments may be utilized and that structuralchanges may be made without departing from the scope of the invention.The following detailed description is, therefore, not to be taken in alimiting sense, and the scope of the present invention is best definedby the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The accompanying drawings, which are hereby incorporated into andconstitute a part of this specification, illustrate preferredembodiments of the invention and, together with the description, serveto explain the principles of the invention. In the drawings wherein likereference numerals represent like parts:

[0028]FIG. 1 is a perspective view of a length of conventionalcontinuously connected fastener stock of the plastic staple variety;

[0029]FIG. 2 is an enlarged end view of an individual plastic stapleobtained from the length of conventional continuously connected fastenerstock of FIG. 1;

[0030]FIG. 3 is a top view of a conventional needle adapted for use indispensing fasteners, such as the plastic staple of FIG. 2;

[0031]FIG. 4 is a left side view of the needle shown in FIG. 3;

[0032]FIG. 5 is a front view of the stem portion of the needle shown inFIG. 3;

[0033]FIG. 6 is a transverse section view of the stem portion of theneedle of FIG. 3, the plastic staple of FIG. 2 being disposedtherewithin;

[0034]FIG. 7 is a side view of a first embodiment of a needleconstructed according to the teachings of the present invention;

[0035]FIG. 8 is a transverse section view of the stem portion of theneedle of FIG. 7, a conventional plastic staple being shown disposedtherein in phantom;

[0036]FIG. 9 is a transverse section view of a second embodiment of astem portion of a needle constructed according to the teachings of thepresent invention;

[0037]FIG. 10 is a fragmentary section view of a plastic fasteneradapted for use in a needle comprising the stem portion of FIG. 9;

[0038]FIG. 11 is a side view of a first embodiment of a length ofplastic staple stock constructed according to the teachings of thepresent invention;

[0039]FIG. 12 is a perspective view of the length of plastic staplestock shown in FIG. 11;

[0040]FIG. 13 is a fragmentary enlarged end view of an individualplastic staple obtained from the length of plastic staple stock of FIG.11;

[0041]FIG. 14 is a fragmentary perspective view of a third embodiment ofa needle constructed according to the teachings of the presentinvention, said needle being adapted for use with the plastic staple ofFIG. 13;

[0042]FIG. 15 is a transverse section view of the needle of FIG. 14, theplastic staple of FIG. 13 being shown disposed therein;

[0043]FIG. 16 is a fragmentary end view of a third embodiment of aplastic staple constructed according to the teachings of the presentinvention;

[0044]FIG. 17 is a transverse section view of a fourth embodiment of aneedle constructed according to the teachings of the present invention,the plastic staple of FIG. 16 being shown disposed therein;

[0045]FIG. 18 is a fragmentary end view of a fourth embodiment of aplastic staple constructed according to the teachings of the presentinvention;

[0046]FIG. 19 is a transverse section view of a fifth embodiment of aneedle constructed according to the teachings of the present invention,the plastic staple of FIG. 18 being shown disposed therein;

[0047]FIG. 20 is a fragmentary end view of a fifth embodiment of aplastic staple constructed according to the teachings of the presentinvention;

[0048]FIG. 21 is a transverse section view of a sixth embodiment of aneedle constructed according to the teachings of the present invention,the plastic staple of FIG. 20 being shown disposed therein;

[0049]FIG. 22 is a fragmentary end view of a sixth embodiment of aplastic staple constructed according to the teachings of the presentinvention; and

[0050]FIG. 23 is a transverse section view of a seventh embodiment of aneedle constructed according to the teachings of the present invention,the plastic staple of FIG. 22 being shown disposed therein.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0051] Referring now to FIG. 1, there is shown a perspective view of alength of conventional continuously connected fastener stock of theplastic staple variety, said length of fastener stock being representedgenerally by reference numeral 11.

[0052] Fastener stock 11, which is made by the above-described rotaryextrusion method and is typically made of polyurethane, comprises twoelongated and continuous side members 13-1 and 13-2. Side members 13-1and 13-2 are coupled together by a plurality of flexible cross-links orfilaments 15, cross-links 15 being equidistantly-spaced apart by adistance of 0.25 inch. By cutting side members 13-1 and 13-2 atappropriate points between cross-links 15, individual fasteners havingan H-shape, often referred to as “plastic staples,” are produced. Eachof the cross-bars of an individual plastic staple has a length of 0.25inch.

[0053] Referring now to FIG. 2, there is shown an enlarged end view ofan individual plastic staple obtained in the aforementioned manner froma length of fastener stock 11, the individual plastic staple beingrepresented generally by reference numeral 21.

[0054] Staple 21 comprises a first cross-bar 23-1, which has been cutfrom side member 13-1, and a second cross-bar 23-2, which has been cutfrom side member 13-2, cross-bars 23-1 and 23-2 being interconnected byflexible filament 15. As can be seen, due to the rotary extrusionprocess by which stock 11 is formed, cross-bars 23-1 and 23-2 andfilament 15 are flat on sides 25-1, 25-2 and 25-3, respectively, sides25-1, 25-2 and 25-3 being coplanar with one another. As a result, as canbe seen, cross-bar 23-1 and filament 15 collectively have a generally“d”-shape when viewed from an end, with cross-bar 23-1 having asubstantially semi-oval shape in cross-section and being generallysymmetric about line 1-1. Cross-bar 23-1 has a transverse width Tw₁greater than its transverse length Tl₁. Cross-bar 23-2 and filament 15also collectively have a generally “d”-shape when viewed from an end,with cross-bar 23-2 being sized and shaped identically to cross-bar23-1.

[0055] Referring now to FIGS. 3 and 4, there are shown top and left sideviews, respectively, of a conventional needle adapted for use indispensing fasteners, such as the plastic staple of FIG. 2, said needlebeing represented generally by reference numeral 51.

[0056] Needle 51 comprises a stem portion 53 and a base portion 55. Stemportion 53 may be made, for example, by stamping and rolling or bymachining a piece of metal (e.g., stainless steel) or by theelectroforming/machining technique described in U.S. Pat. No. 5,489,057,inventor Deschenes, issued Feb. 6, 1996, the disclosure of which isincorporated herein by reference.

[0057] Referring now to FIGS. 3 through 5, stem portion 53 can be seento be an elongated member that is substantially cylindrical over most ofits length (and annular in transverse cross-section). The front end ofstem portion 53 is formed into a spoon-shaped tip 57, tip 57 beingsufficiently sharp to enable its penetration into a desired article ofcommerce. A generally cylindrical bore 59 extends longitudinally acrosssubstantially the entire length of stem portion 53. Bore 59 isappropriately dimensioned to receive a cross-bar of a plastic fastener,such as cross-bar 23-1 of plastic staple 21. Stem portion 53 is alsoshaped to include a slot 61 extending longitudinally acrosssubstantially the entire length of stem portion 53, slot 61 beingappropriately dimensioned to permit a filament, such as filament 15, toextend therethrough while its associated cross-bar is disposed withinbore 59.

[0058] A conventional stamped and rolled stainless steel stem portion 53used in the dispensing of plastic staples 21 typically has a width w₁,of about 0.065 inch and a cross-sectional thickness t₁ of about0.008-0.010 inch.

[0059] Referring back to FIGS. 3 and 4, base portion 55 is made in theconventional manner by insert-molding plastic onto the rear end 60 ofstem portion 53. Base portion 55, which is generally cylindrical inshape, includes a generally cylindrically-shaped longitudinal borealigned with (and sized similarly to) bore 59 of stem portion 53 andalso includes a longitudinal slot aligned with (and sized similarly to)slot 61 of stem portion 53. Base portion 55 is provided with a recessedarea 63 for use in correctly positioning needle 51 within a fastenerdispensing tool and for locking the same into place.

[0060] Referring now to FIG. 6, there is shown a transverse section viewof stem portion 53, with plastic staple 21 being loaded therein. Asdescribed above, the present inventor has noted that, because filament15 and cross-bar 23-1 are flat on sides 25-3 and 25-1, respectively,whereas bore 59 is circular in transverse cross-section and slot 61bisects bore 59 from the top thereof, a considerable portion of bore 59is left unoccupied by staple 21. Consequently, because bore 59 is largerthan necessary to hold staple 21, the overall size or width w₁ of stemportion 53 is unnecessarily large, thereby leading to an insertion holecreated by stem portion 53 that is larger than needed. In addition,because cross-bar 23-1 is much smaller than bore 59 and has considerablefreedom to move laterally within bore 59, the proper translationalmovement of cross-bar 23-1 through bore 59 during ejection cannot beassured.

[0061] Referring now to FIG. 7, there is shown a left side view of afirst embodiment of a needle constructed according to the teachings ofthe present invention, the needle being represented generally byreference numeral 101.

[0062] Needle 101 comprises a stem portion 103 and a base portion 105.Base. portion 105, which is identical in all respects to base portion55, may be made by insert-molding plastic onto the rear end of stemportion 103.

[0063] Stem portion 103 is similar in certain respects to stem portion53. For example, stem portion 103 is an elongated member terminating atits front end in a spoon-shaped tip 107, tip 107 being sufficientlysharp to enable its penetration into a desired article of commerce.However, as shown in FIG. 8, stem portion 103 differs markedly from stemportion 53 in that stem portion 103 has a generally “d”-shapedtransverse cross-section, instead of the generally annular transversecross-section of stem portion 53. As such, stem portion 103 defines agenerally semi-elliptical bore 109 and a generally rectangular slot 111,bore 109 and slot 111 communicating with one another and extendinglongitudinally across substantially the entire length of stem portion103. Bore 109 is bounded on one side thereof by a flat side 109-1 and isbounded on its opposite side by a curved or “single-humped” side 109-2.Slot 111-1 is bounded one on side thereof by a flat side 111-1, flatsides 109-1 and 111-1 lying in the same plane and forming a singlecontinuous wall. Bore 109 is appropriately dimensioned to receive across-bar of a plastic fastener, such as cross-bar 23-1 of plasticstaple 21, and slot 111 is appropriately dimensioned to permit afilament, such as filament 15, to extend therethrough while itsassociated cross-bar is disposed within bore 109.

[0064] As can be seen in FIG. 8, because the shape of stem portion 103more closely conforms to that of staple 21, the amount of unoccupied orwasted space in bore 109 is considerably less than that in bore 59, andthe overall size or width w₂ of stem portion 103 can be made to besmaller than that for stem portion 53. Moreover, because of thetruncated shape of bore 109, cross-bar 23-1 has much less freedom tomove laterally within bore 109 as it is being ejected therefrom.Furthermore, because slot 111 is shaped so as to surround comparativelymore of the length of filament 15 than does slot 61, staple 21 isafforded increased protection against becoming broken in the vicinity ofthe juncture between filament 15 and cross-bar 23-1.

[0065] Stem portion 103 may be made by extrusion or by any of the sametechniques discussed above in connection with the fabrication of stemportion 53; however, the above-described electroforming/machiningtechnique is preferred. Said electroforming step is preferably performedusing a suitably shaped master (e.g., a “d”-shaped master) andpreferably involves depositing a boron/nickel (or steel) alloy onto themaster to a substantially uniform thickness of about 0.003-0.005 inch.One of the advantages of using electroforming and the aforementionedboron/nickel alloy to form stem portion 103 is that the cross-sectionalthickness t₂ of stem portion 103 can be kept smaller than that for stemportion 53 (i.e., about 0.003-0.005 inch versus about 0.008-0.010 inch),without a concurrent loss in strength (or even with an improvement instrength). This reduction in the cross-sectional thickness of stemportion 103, together with the truncated shape of stem portion 103,permits the overall size or width w₂ of stem portion 103 to be kept to aminimum (e.g., about 0.050 inch for stem portion 103 versus about 0.065inch for stem portion 53).

[0066] Referring now to FIG. 9, there is shown a transverse section viewof a second embodiment of a stem portion of a needle constructedaccording to the teachings of the present invention, the stem portionbeing represented generally by reference numeral 151.

[0067] Stem portion 151 is identical in virtually all respects to stemportion 103, the principal difference between stem portion 151 and stemportion 103 being that stem portion 151 is shaped to define a generallyrectangular bore 153, instead of the generally semi-elliptical bore 109of stem portion 103. Bore 153 has a transverse cross-sectional height h₁and a transverse cross-sectional width W₃, height h₁ being greater thanwidth W₃ and extending parallel to the length of a filament in slot 155.

[0068] Stem portion 151 is preferably made in the same manner as stemportion 103, and a suitably shaped base portion (not shown) ispreferably insert-molded onto the rear end of stem portion 151 in theconventional manner.

[0069] Because of the generally rectangular transverse cross-sectionalshape of bore 153, stem portion 151 is particularly well-suited for usewith a plastic fastener having a complementary generally rectangularcross-sectional shape. An example of such a fastener is shown in FIG. 10and is represented generally by reference numeral 171. As compared tocross-bar 23-1, cross-bar 173 of fastener 171 has a substantiallyrectangular cross-section, rather than a substantially semi-oval shapedcross-section, and has a comparatively increased transversecross-sectional length Tl₂ and a comparatively decreased transversecross-sectional width Tw₂, with length Tl₂ being larger than width Tw₁.The overall masses of cross-bar 23-1 and cross 173 are generallyequivalent. The increased transverse cross-sectional height endowscross-bar 173 with increased strength to resist collapsing towards itsmidpoint and being withdrawn through an article when a withdrawing forceis applied to filament 175 (a phenomenon known in the art as “Y”-ing).

[0070] Referring now to FIGS. 11 and 12, there are shown side andperspective views, respectively, of a first embodiment of a length ofplastic staple stock constructed according to the teachings of thepresent invention, said length of plastic staple stock being representedgenerally by reference numeral 201.

[0071] Stock 201, which is preferably made a rotary extrusion method ofthe type described above and which is preferably made of polyurethane orthe like, comprises two elongated and continuous side members 203-1 and203-2. Side members 203-1 and 203-2 are coupled together by a pluralityof flexible cross-links or filaments 205, cross-links 205 beingequidistantly-spaced apart by a distance of about 0.18 inch. By cuttingside members 203-1 and 203-2 at appropriate points between cross-links205, individual fasteners having an overall H-shape and a cross-barlength of about 0.18 inch are produced. One advantage of stock 201having a pitch of about 0.18 inch, as opposed to the 0.25 pitch of stock11, is that the number of fasteners per unit length of stock is greaterin stock 201 than in stock 11, thereby permitting more fasteners to befitted to a length of stock 201 than to a comparable length of stock 11.One would not want to further reduce the pitch of the stock much morebeyond 0.18 inch (i.e., in the vicinity of 0.1 inch) since, for manyapplications, a cross-bar much shorter than about 0.18 inch is too shortto be retained in an item and will too easily be withdrawn through theitem when subjected to a substantial withdrawal force.

[0072] Referring now to FIG. 13, there is shown a fragmentary enlargedend view of an individual plastic staple obtained in the aforementionedmanner from a length of fastener stock 201, the individual plasticstaple being represented generally by reference numeral 221.

[0073] Staple 221 comprises a first cross-bar 223-1, which has been cutfrom side member 203-1, and a second cross-bar 223-2, which has been cutfrom side member 203-2, cross-bars 223-1 and 223-2 being interconnectedby flexible filament 205. As can be seen, due to the rotary extrusionprocess by which stock 201 is formed, cross-bars 223-1 and 223-2 andfilament 205 are flat on sides 225-1, 225-2 and 225-3, respectively,with sides 225-1, 225-2 and 225-3 being coplanar with one another. Ascan also be seen, cross-bars 223-1 and 223-2 are shaped to include apair of protrusions or humps on sides 225-4 and 225-5, respectively.Consequently, each of cross-bars 223-1 and 223-2 has a generally“B”-shape when viewed from the ends thereof.

[0074] Referring now to FIG. 14, there is shown a fragmentaryperspective view of a third embodiment of a needle constructed accordingto the teachings of the present invention, said needle being representedgenerally by reference numeral 251.

[0075] Needle 251 comprises a stem portion 253 and a base portion (notshown), said base portion being similar to base portion 55 andpreferably being made by insert-molding plastic onto the rear end ofstem portion 253.

[0076] Stem portion 253 is similar in many respects to stem portion 103.For example, stem portion 253 is an elongated member terminating at itsfront end in a spoon-shaped tip 257, tip 257 being sufficiently sharp toenable its penetration into a desired article of commerce. However, asseen best in FIG. 15, stem portion 253 differs primarily from stemportion 103 in that stem portion 253 has a longitudinal bore 259 of agenerally “B”-shaped transverse cross-section, instead of the generallysemi-elliptical bore 109 of stem portion 103. Bore 259 is bounded on oneside thereof by a flat side 259-1 and on an opposite side thereof by acurved or “double-humped” side 259-2. Stem portion 253 defines alongitudinal slot 261 bounded one on side thereof by a flat side 261-1,flat sides 259-1 and 261-1 lying in the same plane and forming a singlecontinuous wall. Bore 259 is appropriately dimensioned to receive across-bar of a plastic staple, such as cross-bar 223-2 of plastic staple221, and slot 261 is appropriately dimensioned to permit a filament,such as filament 205, to extend therethrough while its associatedcross-bar is disposed within bore 259. The outer width of stem portionis about 0.042 inch.

[0077] Many of the advantages discussed above that result from the useof needle 101 with conventional plastic staples also result from the useof staple 221 and needle 251.

[0078] Referring now to FIG. 16, there is shown a fragmentary end viewof a third embodiment of an individual plastic staple constructedaccording to the teachings of the present invention, said plastic staplebeing referred to generally by reference numeral 301.

[0079] Staple 301 is similar in virtually all respects to staple 221,staple 301 comprising a pair of mirror image cross-bars (only firstcross-bar 303-1 being shown) interconnected by a flexible filament 305.As can be seen, cross-bar 303-1 and filament 305 are flat on sides 307-1and 307-2, with sides 307-1 and 307-2 being coplanar with one another.As can also be seen, cross-bar 303-1 is shaped to include a pair ofprotrusions or humps 311-1 and 311-2 on opposite side 309-1, humps 311-1and 311-2 being spaced further apart than the corresponding humps oncross-bar 223.

[0080] Referring now to FIG. 17, staple 301 is shown inserted into thestem portion 321 of a needle. Stem portion 321 is similar in virtuallyall respects to stem portion 253 of needle 251, stem portion 321 beingan elongated member terminating at its front end in a spoon-shaped tipand being shaped to include a longitudinal bore 323 and a longitudinalslot 325. Bore 323, which has a generally “B”-shaped transversecross-section, is bounded on one side thereof by a flat side 327-1 andon an opposite side thereof by a curved or “double-humped” side 327-2.Slot 325 is bounded one on side thereof by a flat side 329-1, flat sides327-1 and 329-1 lying in the same plane and forming a single continuouswall. Stem portion 321 differs from stem portion 253 only in that bore323 is appropriately shaped to conform to the shape of side 309-1 ofcross bar 303-1, as opposed to side 225-4 of cross-bar 223-1.

[0081] Referring now to FIG. 18, there is shown a fragmentary end viewof a fourth embodiment of an individual plastic staple constructedaccording to the teachings of the present invention, said plastic staplebeing referred to generally by reference numeral 401.

[0082] Staple 401 is similar in many respects to staple 221, staple 401comprising a pair of mirror image cross-bars (only first cross-bar 403-1being shown) interconnected by a flexible filament 405. As can be seen,cross-bar 403-1 and filament 405 are flat on sides 407-1 and 407-2, withsides 407-1 and 407-2 being coplanar with one another. As can also beseen, cross-bar 403-1 is shaped to include a sloped side 411 opposite toside 407-1, sloped side 411 giving cross-bar 403-1 a generallywedge-shaped transverse cross-section.

[0083] Referring now to FIG. 19, staple 401 is shown inserted into thestem portion 421 of a needle. Stem portion 421 is similar in manyrespects to stem portion 253 of needle 251, stem portion 421 being anelongated member terminating at its front end in a spoon-shaped tip andbeing shaped to include a longitudinal bore 423 and a longitudinal slot425. Bore 423, which has a generally wedge-shaped transversecross-section, is bounded on one side thereof by a flat side 427-1 andon an opposite side thereof by a sloped side 427-2. Slot 425 is boundedone on side thereof by a flat side 429-1, flat sides 427-1 and 429-1lying in the same plane and forming a single continuous wall. As can beseen, bore 423 of stem portion 421 is appropriately shaped to conform tothe shape of cross bar 403-1.

[0084] Referring now to FIG. 20, there is shown a fifth embodiment of anindividual plastic staple constructed according to the teachings of thepresent invention, said plastic staple being referred to generally byreference numeral 501.

[0085] Staple 501 is similar in virtually all respects to staple 301,staple 501 comprising a pair of mirror image cross-bars (only firstcross-bar 503-1 being shown) interconnected by a flexible filament 505.As can be seen, cross-bar 503-1 and filament 505 are flat on sides 507-1and 507-2, with sides 507-1 and 507-2 being coplanar with one another.As can also be seen, cross-bar 503-1 is shaped to include a pair ofprotrusions or humps 511-1 and 511-2 on opposite side 509-1, humps 511-1and 511-2 differing from humps 311-1 and 311-2 of staple 301 in thathump 511-1 protrudes further away from side 507-1 than does hump 511-2.

[0086] Referring now to FIG. 21, staple 501 is shown inserted into thestem portion 521 of a needle. Stem portion 521 is similar in virtuallyall respects to stem portion 321, stem portion 521 being an elongatedmember terminating at its front end in a spoon-shaped tip and beingshaped to include a longitudinal bore 523 and a longitudinal slot 525.Bore 523, which has a generally “B”-shaped transverse cross-section, isbounded on one side thereof by a flat side 527-1 and on an opposite sidethereof by a curved or “double-humped” side 527-2. Slot 525 is boundedone on side thereof by a flat side 529-1, flat sides 527-1 and 529-1lying in the same plane and forming a single continuous wall. Stemportion 521 differs from stem portion 321 only in that bore 523 isappropriately shaped to conform to the shape of side 509-1 of cross bar503-1, as opposed to side 309-1 of cross-bar 303-1.

[0087] Referring now to FIG. 22, there is shown a fragmentary end viewof a sixth embodiment of an individual plastic staple constructedaccording to the teachings of the present invention, said plastic staplebeing referred to generally by reference numeral 601.

[0088] Staple 601 is similar in many respects to staple 401, staple 601comprising a pair of mirror image cross-bars (only first cross-bar 603-1being shown) interconnected by a flexible filament 605. As can be seen,cross-bar 603-1 and filament 605 are flat on sides 607-1 and 607-2, withsides 607-1 and 607-2 being coplanar with one another. As can also beseen, cross-bar 603-1 is shaped to include a protrusion or hump 609 on aside 611 opposite to side 607-1.

[0089] Referring now to FIG. 23, staple 601 is shown inserted into thestem portion 621 of a needle. Stem portion 621 is similar in manyrespects to stem portion 421, stem portion 621 being an elongated memberterminating at its front end in a spoon-shaped tip and being shaped toinclude a longitudinal bore 623 and a longitudinal slot 625. Bore 623 isbounded on one side thereof by a flat side 627-1 and on an opposite sidethereof by a side 627-2 shaped to conform to side 611 of cross-bar603-1. Slot 625 is bounded one on side thereof by a flat side 629-1,flat sides 627-1 and 629-1 lying in the same plane and forming a singlecontinuous wall.

[0090] The embodiments of the present invention recited herein areintended to be merely exemplary and those skilled in the art will beable to make numerous variations and modifications to it withoutdeparting from the spirit of the present invention. All such variationsand modifications are intended to be within the scope of the presentinvention as defined by the claims appended hereto.

What is claimed is:
 1. A needle well-suited for use in dispensingplastic fasteners of the type comprising a filament having a cross-barat a first end thereof, said needle comprising a stem portion, said stemportion terminating in a tip at a front end thereof and being shaped todefine a longitudinally-extending bore and a longitudinally-extendingslot, said longitudinally-extending bore being dimensioned to receivesaid cross-bar, said longitudinally-extending slot being dimensioned topermit said filament to extend therethrough while said cross-bar isdisposed within said longitudinally-extending bore, saidlongitudinally-extending bore having a first flat side, saidlongitudinally-extending slot having a first flat side, said first flatsides of said longitudinally-extending bore and saidlongitudinally-extending slot being coplanar.
 2. The needle as claimedin claim 1 wherein said longitudinally-extending bore and saidlongitudinally-extending slot collectively have a “d”-shaped transversecross-section.
 3. The needle as claimed in claim 1 wherein said stemportion has a “d”-shaped transverse cross-section.
 4. The needle asclaimed in claim 2 wherein said longitudinally-extending bore has agenerally semi-elliptical transverse cross-section.
 5. The needle asclaimed in claim 2 wherein said longitudinally-extending bore has agenerally rectangular transverse cross-section.
 6. The needle as claimedin claim 5 wherein said generally rectangular transverse cross-sectionhas a height parallel to said first flat side of saidlongitudinally-extending bore and a width perpendicular to said firstflat side of said longitudinally-extending bore, said height beinggreater than said width.
 7. The needle as claimed in claim 1 whereinsaid stem portion has an outer width of about 0.042-0.050 inch.
 8. Theneedle as claimed in claim 1 wherein said stem portion has across-sectional thickness of about 0.003-0.005 inch.
 9. The needle asclaimed in claim 1 wherein said stem portion is fabricated usingelectroforming.
 10. The needle as claimed in claim 9 wherein said stemportion is made of a boron/nickel alloy.
 11. The needle as claimed inclaim 1 further comprising a base portion, said base portion beinginsert-molded onto a rear end of said stem portion.
 12. The needle asclaimed in claim 1 wherein said bore further has a second side oppositeto said first flat side, said second side being shaped to include atleast one curved portion.
 13. The needle as claimed in claim 12 whereinsaid second side is shaped to include a pair of humps.
 14. The needle asclaimed in claim 12 wherein one of said pair of humps extends furtherthan the other of said humps.
 15. The needle as claimed in claim 1wherein said bore has a generally “B”-shaped transverse cross-section.16. The needle as claimed in claim 1 wherein said bore has a generallywedge-shaped transverse cross-section.
 17. A method of fabricating aneedle well-suited for use in the dispensing of plastic fasteners of thetype comprising a filament having a cross-bar at a first end thereof,said method comprising the steps of: (a) fabricating an unfinished stemportion, said fabricating step comprising electroforming a metal onto amaster, said master having a “d”-shaped transverse cross-section, andthen removing the master from the electroformed metal; and (b) finishingsaid unfinished stem portion, said finishing step comprising machiningthe unfinished stem portion to yield a finished stem portion, saidfinished stem portion terminating in a tip at a front end and beingshaped to define a longitudinally-extending bore and alongitudinally-extending slot, said longitudinally-extending bore beingshaped to receive said cross-bar, said longitudinally-extending slotbeing shaped to permit said filament to extend therethrough while saidcross-bar is disposed within said longitudinally-extending bore, saidlongitudinally-extending bore and said longitudinally-extending slotcollectively having a “d”-shaped transverse cross-section.
 18. Themethod as claimed in claim 17 wherein said metal is a boron/nickelalloy.
 19. The method as claimed in claim 17 further comprisinginsert-molding a base portion onto a rear end of the finished stemportion.
 20. The method as claimed in claim 17 wherein saidelectroforming step comprises depositing metal onto said master to athickness of about 0.003-0.005 inch.
 21. A method of fabricating aneedle well-suited for use in the dispensing of plastic fasteners of thetype comprising a filament having a cross-bar at a first end thereof,said method comprising the steps of: (a) fabricating an unfinished stemportion, said fabricating step comprising electroforming a metal onto amaster, said master having a flat side in transverse cross-section, andthen removing the master from the electroformed metal; and (b) finishingsaid unfinished stem portion, said finishing step comprising machiningthe unfinished stem portion to yield a finished stem portion, saidfinished stem portion terminating in a tip at a front end and beingshaped to define a longitudinally-extending bore and alongitudinally-extending slot, said longitudinally-extending bore beingshaped to receive said cross-bar, said longitudinally-extending slotbeing shaped to permit said filament to extend therethrough while saidcross-bar is disposed within said longitudinally-extending bore, saidlongitudinally-extending bore and said longitudinally-extending sloteach having a flat side in transverse cross-section, said flat sides ofsaid longitudinally-extending bore and said longitudinally-extendingslot being coplanar.
 22. A needle comprising a stem portion, said stemportion terminating at a front end thereof in a tip, said stem portionhaving a longitudinally extending slotted bore, said longitudinallyextending slotted bore having a flat side in transverse cross-section.23. The needle as claimed in claim 22 wherein said longitudinallyextending slotted bore is “d”-shaped in transverse cross-section. 24.The needle as claimed in claim 23 wherein said stem portion has an outerwidth of about 0.050 inch.
 25. The needle as claimed in claim 23 whereinsaid stem portion has a cross-sectional thickness of about 0.003-0.005inch.
 26. The needle as claimed in claim 22 further comprising a baseportion, said base portion being insert-molded onto a rear end of thestem portion.
 27. A combination of a plastic fastener and a needle, saidplastic fastener comprising a flexible filament having a cross-bar at afirst end thereof, said cross-bar and said flexible filamentcollectively having a generally “d”-shaped cross-section taken along thelength of said flexible filament and transverse to the length of saidcross-bar, said needle comprising a stem portion, said stem portionterminating in a tip at a front end thereof and being shaped to define alongitudinally-extending bore and a longitudinally-extending slot, saidlongitudinally-extending bore being dimensioned to receive saidcross-bar, said longitudinally-extending slot being dimensioned topermit said flexible filament to extend therethrough while saidcross-bar is disposed within said longitudinally-extending bore, saidlongitudinally-extending bore and said longitudinally-extending slotcollectively having a generally “d”-shaped transverse cross-section. 28.The combination as claimed in claim 27 wherein said cross-bar isgenerally semi-elliptical in transverse cross-sectional shape.
 29. Thecombination as claimed in claim 27 wherein said cross-bar is generallyrectangular in transverse cross-sectional shape.
 30. The combination asclaimed in claim 29 wherein said cross-bar has a transversecross-sectional height and a transverse cross-sectional width, saidtransverse cross-sectional height being greater than said transversecross-sectional width and being parallel to the length of said flexiblefilament.
 31. The combination as claimed in claim 27 wherein saidplastic fastener is part of a length of continuously connected fastenerstock made by rotary extrusion.
 32. A needle comprising a stem portion,said stem portion terminating at a front end in a tip, said stem portionhaving a longitudinally extending slotted bore, said longitudinallyextending slotted bore being asymmetric in transverse cross-section. 33.The needle as claimed in claim 32 wherein said longitudinally extendingslotted bore is shaped to include a generally “B”-shaped portion intransverse cross-section.
 34. The needle as claimed in claim 32 whereinsaid longitudinally extending slotted bore is shaped to include agenerally wedge-shaped portion in transverse cross-section.
 35. Theneedle as claimed in claim 32 wherein said longitudinally extendingslotted bore is generally “d”-shaped in transverse cross-section. 36.The needle as claimed in claim wherein said longitudinally extendingslotted bore is shaped in transverse cross-section to include a flatside.
 37. The needle as claimed in claim 36 wherein said longitudinallyextending slotted bore is further shaped in transverse cross-section toinclude a side having at least one hump.
 38. A plastic fastenercomprising a flexible filament having a cross-bar at a first endthereof, said cross-bar and said flexible filament collectively having agenerally “d”-shaped cross-section taken along the length of saidflexible filament and transverse to the length of said cross-bar, saidcross-bar having a substantially rectangular cross-sectional shape withits transverse length being larger than its transverse width.
 39. Theplastic fastener as claimed in claim 38 wherein said cross-bar has alength of about 0.18 inch.
 40. A length of fastener stock, said lengthof fastener stock comprising a pair of continuous side members and aplurality of flexible cross-links interconnecting said continuous sidemembers, said flexible cross-links being equidistantly-spaced apart at apitch of about 0.18 inch.
 41. The length of fastener stock as claimed inclaim 40 wherein said continuous side members are parallel to oneanother and wherein said flexible cross-links are perpendicular to eachof said continuous side members.
 42. The length of fastener stock asclaimed in claim 41 wherein each of said continuous side members has aflat side and wherein each of said flexible cross-links has a flat sideand wherein said flat sides of said continuous side members and saidflexible cross-links are coplanar.
 43. The length of fastener stock asclaimed in claim 42 wherein each of said continuous side members issemi-elliptical in transverse cross-section.
 44. The length of fastenerstock as claimed in claim 42 wherein at least one of said continuousside members is “B”-shaped in transverse cross-section.
 45. The lengthof fastener stock as claimed in claim 42 wherein at least one of saidcontinuous side members is wedge-shaped in transverse cross-section. 46.The length of fastener stock as claimed in claim 42 wherein at least oneof said continuous side members has a second side opposite to said flatside, said second side including at least one hump.
 47. The length offastener stock as claimed in claim 46 wherein said second side has apair of humps.
 48. The length of fastener stock as claimed in claim 47wherein one of said pair of humps protrudes further than the other ofsaid pair of humps.
 49. An individual plastic fastener separated fromthe length of fastener stock claimed in claim
 42. 50. A length offastener stock, said length of fastener stock comprising a plurality offasteners, each of said fasteners comprising a flexible filament and across-bar disposed at one end of said flexible filament, said cross-barhaving a “B”-shape in transverse cross-section.
 51. The length offastener stock as claimed in claim 50 wherein said cross-bar has a pairof humps, said humps protruding equally.
 52. A length of fastener stock,said length of fastener stock comprising a pair of continuous sidemembers and a plurality of flexible cross-links interconnecting saidcontinuous side members, at least one of said continuous side membershaving a “B”-shape in transverse cross-section.
 53. An individualplastic fastener separated from the length of fastener stock claimed inclaim
 52. 54. The length of fastener stock as claimed in claim 52wherein both of said continuous side members has a “B”-shape intransverse cross-section.
 55. The length of fastener stock as claimed inclaim 52 wherein each of said continuous side members has a flat sideand wherein each of said flexible cross-links has a flat side andwherein said flat sides of said continuous side members and saidflexible cross-links are coplanar.
 56. A combination of a plasticfastener and a needle, said plastic fastener comprising a flexiblefilament having a cross-bar at a first end thereof, said cross-barhaving a length of about 0.18 inch and having a “B”-shaped transversecross-section, said needle comprising a stem portion, said stem portionterminating in a tip at a front end thereof and being shaped to define alongitudinally-extending bore and a longitudinally-extending slot, saidlongitudinally-extending bore being dimensioned to receive saidcross-bar, said longitudinally-extending slot being dimensioned topermit said flexible filament to extend therethrough while saidcross-bar is disposed within said longitudinally-extending bore, saidlongitudinally-extending bore having a generally “B”-shaped transversecross-section.
 57. The combination as claimed in claim 56 wherein eachof said cross-bar and said flexible filament has a flat side and whereinsaid flat sides of said cross-bar and said flexible filament arecoplanar.
 58. The combination as claimed in claim 57 wherein each ofsaid longitudinally-extending slot and said longitudinally-extendingbore has a flat side and wherein said flat sides of saidlongitudinally-extending slot and said longitudinally-extending bore arecoplanar.
 59. A length of fastener stock, said length of fastener stockcomprising a pair of continuous side members and a plurality of flexiblecross-links interconnecting said continuous side members, at least oneof said continuous side members being wedge-shaped in transversecross-section.
 60. A combination of a plastic fastener and a needle,said plastic fastener comprising a flexible filament having a firstcross-bar at a first end thereof, each of said flexible filament andsaid first cross-bar having a flat side, said flat sides of saidflexible filament and said first cross-bar being coplanar, said firstcross-bar further having an opposite side including a curved portion,said needle comprising a stem portion, said stem portion terminating ina tip at a front end thereof and being shaped to define alongitudinally-extending bore and a longitudinally-extending slot, saidlongitudinally-extending bore and said longitudinally-extending slotbeing shaped to conform to said flexible filament and said firstcross-bar.
 61. The combination as claimed in claim 60 wherein said firstcross-bar is “B”-shaped in transverse cross-section.
 62. The combinationas claimed in claim 60 wherein said first cross-bar is wedge-shaped intransverse cross-section.
 63. The combination as claimed in claim 60wherein said first cross-bar and said flexible filament are collectively“d”-shaped in transverse cross-section.